Projects

Power Generation Plant – Primary Mechanical Package

PCMIS was awarded the competitive bid for the Primary Mechanical Work Package for a 624 MW super-critical coal-fired power generation unit (#2) for NRG Energy in southern MD, spring of 2013. This work consisted of scheduled maintenance, repairs (mechanical & welding) and/or replacement of components associated with the following systems: Air Preheater, CE/Raymond Pulverizers, Traveling Screens & Circulating Water Pumps, FD/ID Fans, Fuel Burners, Bottom-Ash Drag Chain Conveyor, Fuel Distribution Piping, HP & LP Heater Exchangers, Steam-Turbine Condenser and High Energy Piping. PCMIS self-performed all project management, supervision and craft work which was successfully completed on schedule during a planned 8 week shut down. Utilizing a workforce of 93 craftsmen, PCMIS worked 38,000 man-hours, completing all phases of this project with no re-work. Notable during this project, PCMIS passed the 1,000,000 man-hour mark of maintenance & repair work completed on Air Preheater units since its establishment in 1986.

Carbon Calciner Plant – Wastewater Treatment Facility

PCMIS was contracted on a Time & Material basis to perform all civil, mechanical and electrical work required for construction of a wastewater treatment facility at the Rain CII Carbon Calciner Plant in Moundsville, WV. PCMIS self-performed all project management, supervision and craft work, with engineering provided by the owner. PCMIS completed this project on schedule with 10-13 craftsmen utilizing 6,906 man-hours with zero injuries. The civil work included PCMIS installing 451 tons of stone, 21,000 feet of rebar and 221 yards of concrete prior to erecting a 3,000 square foot building. PCMIS’ workforce provided a true turn-key project by performing all equipment operation, masonry, rigging, erection, assembly, fabrication, termination and commissioning.

Power Generation Plant – Primary Mechanical Package

PCMIS was awarded the competitive bid for the Primary Mechanical Work Package for a 624 MW super-critical coal-fired power generation unit (#1) for NRG Energy in southern MD, spring of 2012. This work consisted of scheduled maintenance, repairs (mechanical & welding) and/or replacement of components associated with the following systems: Air Preheater, CE/Raymond Pulverizers, FD/ID Fans, Fuel Burners, Bottom-Ash Drag Chain Conveyor, Fuel Distribution Piping, HP & LP Heat Exchangers, Steam-Turbine Condenser, High Energy Piping and Flue-gas Desulfurization (Scrubber) System. PCMIS self-performed all project management, supervision and craft work which was successfully completed on schedule during a planned 9 week shut down. Utilizing a workforce of 83 craftsmen, PCMIS worked 31,000 man-hours, completing all phases of this project with no re-work and an excellent safety performance.

Power Generation Plant – Superheater Bypass Valve

Replacement of a critical Superheater Bypass Valve at a 2600 MW coal-fired plant in southern MD was awarded to PCMIS based on a successful competitive bid. This project included the removal and installation of a new 2500 PSI Superheater Bypass Valve, structural repairs, rigging and in-place machining. All code work was done in accordance with ASME Section I: Boiler & Pressure Vessel Code, ASME B31.1: Power Piping. This project also included structural welding repairs completed in accordance with AWS D.1: Structural Weld Repairs. PCMIS safely completed this project on schedule with 10-12 craftsmen in just over 3,000 man-hours. All ASME welds were radiography tested with a 100% pass rate. A properly signed/executed R-1 Form was supplied to Mirant upon project completion. All phases of this project were self-performed.

PCMIS was awarded an extended “Service Agreement” contract to supply all supervision and craft personnel needed to complete all preventative maintenance, shutdown inspections and resulting repairs, as well as pre-planned scheduled overhauls of the existing six (6) Coal Feeders and Pulverizers for Dominion Generation @ its Chesterfield Power Station in eastern Virginia. The agreement also included the replacement and, when necessary, fabrication of 10″ and 14” Fuel Piping (75 pcs.) on two (2) 491 MW coal-fired units. These combined projects were completed on schedule over an 18 week period, with no safety incidents.

Stainless Steel Finishing Plant – Sulfuric Acid Tank & Piping

PCMIS replaced the Sulfuric Acid Process Tub (28,000 lbs.) and Re-circulation Tank (19,000 lbs.) on the 52″ Annealing & Pickling Line, including all associated feed, drain, suction and make-up water piping. Four (4) Ansi-Mag pumps and eight (8) Automax valves were also replaced at the ATI Allegheny Ludlum plant in Vandergrift, PA. This work included welding, millwright, pipefitting and heavy rigging; all self-performed by PCMIS craftsmen and completed on a Time & Material basis in ten (10) days with zero safety incidents.

Power Generation Plant – Feed Pump Upgrades

PCMIS self-performed upgrades to the existing boiler feed pumps (2) at a 1500 MW coal-fired plant in southern MD. This project was completed on a firm price basis per a negotiated contract with INVENSYS, an industrial automation company. Upgrades consisted of the installation of two (2) high-pressure control valves w/ hydraulic control valve panels, high-pressure stop valve actuator cylinders and low-pressure stop valve actuator cylinders. Additionally, PCMIS fabricated and installed all necessary stainless steel piping, tubing and Swagelok components on each unit.

Power Generation Plant – Air Preheater Rebuild

PCMIS, through competitive bidding, was awarded a firm price contract to rebuild one (1) vertical shaft air preheater wheel on a 96 MW gas-fired Dominion Generation unit in northern VA, which had sustained major damage due to a fire. The work scope consisted of the demolition of all the existing super-structure down to the rotor-post, then the rebuild consisting of installing new diaphragms, hot/intermediate/cold heating elements (baskets), circumferential radial, rotor post seals, inspection of upper and guide bearings and associated ductwork. All work was self-performed by PCMIS with the exception of NDE with no safety incidents.

Nutrition Facility – Welding / Mechanical

Based on reputation, PCMIS was awarded a Time and Material contract to complete inspections on (16) stainless steel processing tanks and make weld repairs as needed. All welding was completed by ASME certified welders. In addition, two finished product and one in-process conveyor lines were overhauled replacing belts, bearings, structural supports, and micro switches.